Apparatus and a method are presented for determining the torque load applied to a fastening element by a fluid powered wrench, and displaying a digital readout of the torque. The operating pressure of the wrench, after compensation for the temperature of the pressure transducer, is converted to a torque...http://www.google.com/patents/US4791839?utm_source=gb-gplus-sharePatent US4791839 - Apparatus and method for determining torque and presenting digital torque readout in a torque wrench system

Apparatus and method for determining torque and presenting digital torque readout in a torque wrench systemUS 4791839 A

Abstract

Apparatus and a method are presented for determining the torque load applied to a fastening element by a fluid powered wrench, and displaying a digital readout of the torque. The operating pressure of the wrench, after compensation for the temperature of the pressure transducer, is converted to a torque measurement by programmed microprocessor and the torque value is displayed on a digital readout. The system is useable with and adjusts for wrenches of several sizes by an input selector switch connected to the microprocessor.

Images(6)

Claims(17)

What is claimed is:

1. An apparatus for determining torque and representing digital torque readout in a torque wrench system, the torque wrench system including a fluid powered torque wrench supplied by fluid from a pump and further comprising:

pressure sensing means for sensing the pressure level of the pump and generating a pressure level voltage signal;

converter means for converting said pressure level voltage signal from an analog signal to a digital signal;

temperature sensing means for sensing the temperature of the pressure sensing means, and for generating a temperature compensation signal to said microprocessor means;

wrench size selector switch means for delivering a wrench size signal to said microprocessor means wherein said wrench size signal is based on the size of the wrench used in the wrench system; and

digital display means associated with said microprocessor means wherein said microprocessor means processes said pressure level voltage signal, temperature compensation signal and wrench size signal and wherein said microprocessor generates a digital output of the real time torque level of the torque wrench, said real time torque level being displayed on said digital display means.

amplifier means connected to receive said pressure level voltage signal and generate an output signal commensurate with the pressure level;

comparator means connected to receive an output signal from said amplifier means commensurate with the pressure relief;

digital to analog converter means connected to receive a sequence of digital voltage signals from said micorprocessor and to deliver said signals in sequence to said comparator means for comparison with said output signal from said amplifier means commensurate with the pressure level; and

said comparator means being connected to said microprocessor means to deliver a signal to said microprocessor means when the digital voltage signal to said comparator means and the amplifier means output signal to said comparator means are approximately equal.

6. The apparatus of claim 5 further including:

multiplexer means, said multiplexer means being connected to receive said output signal from said amplifier means commensurate with pressure and also being connected to receive a voltage signal from said temperature sensor means commensurate with temperature;

said multiplexer means being connected to and controlled by said microprocessor means to selectively deliver signals commensurate with pressure or temperature to said comparator means; and

said converter means, under the control of said microprocessor means, selectively delivering a sequence of digital voltage signals to said comparator means for comparison with inputs to said comparator means from said multiplexer means commensurate with either pressure or temperature.

switch multiplexer means connected to said switch selector means and connected to said microprocessor means, said switch multiplexer means having a plurality of inputs from said microprocessing means and one output to said microprocessor; and

each of said switch positions being connected to a unique combination of said inputs in said switch multiplexer means to define a binary code for each switch position which can be determined by said micorprocessor means to determine the switch selected.

switch multiplexer means connected to said switch selector means and connected to said microprocessor means, said switch multiplexer means having a plurality of inputs from said microprocessor means and one output to said microprocessor; and

each of said switch positions being connected to a unique combination of said inputs in said switch multiplexer means to define a binary code for each switch position which can be determined by said microprocessor means to determine the switch selected.

9. A method for determining torque and presenting digital torque readout in a torque wrench system, the torque wrench system including a fluid powered torque wrench supplied by fluid from a pump and comprising the steps of:

sensing the pressure level of the pump using pressure level sensing means and generating a pressure level voltage signal;

converting said pressure level voltage signal from an analog signal to a digital signal;

sensing the temperature at which the pressure level sensing means is operating using temperature sensing means, and generating a temperature compensation signal for delivery to said microprocessor means;

delivering a wrench size signal to said microprocessor means wherein said wrench size signal is based on the size of the wrench used in the wrench system;

processing said pressure level voltage signal, temperature compensation signal and wrench size signal in said microprocessor means wherein said microprocessor generates a ditigal output of the real time torque level of the torque wrench; and

displaying and real time torque level on digital display means associated with said microprocessor means.

delivering a signal to said multiplexer means from said microprocessor means to select either said pressure level voltage signal or said temperature compensation signal for comparison with a sequence of digital voltage signals from said microprocessor means.

15. The method of claim 14 wherein the steps of delivering a wrench size signal includes:

assigning a unique binary code to each wrench size commensurate with positions of a multiple position selection switch;

interrogating to determine the binary code activated by the position of the switch; and

informing the microprocessor means of the binary code.

16. The method of claim 9 wherein the steps of delivering a wrench size signal includes:

assigning a unique binary code to each wrench size commensurate with positions of a multiple position selection switch;

interrogating to determine the binary code activated by the position of the switch; and

informing the microprocessing means of the binary code.

17. The method of claim 9 further including the step of:

presetting the maximum operating pressure of the torque wrench system by setting a pressure relief valve based on a torque level displayed on said digital display means.

Description

FIELD OF THE INVENTION

This invention relates to the field of fluid powered torque wrenches. More particularly, this invention relates to the field of torque measurement of fluid powered torque wrenches.

DISCUSSION OF THE PRIOR ART

Fluid powered torque wrenches are well known in the art. By way of example, one type of ratcheting, hydraulically powered torque wrench is disclosed in U.S. Pat. No. 3,745,858. An improved version of that torque wrench is disclosed in Application Ser. No. 745,404, filed June 14, 1985. Both U.S. Pat. No. 3,745,858 and Application Ser. No. 745,404 are owned by the assignee hereof and are incorporated hereinby reference.

In operating hydraulic torque wrench systems, it is important to know the output, i.e., the torque, generated by the wrench. Prior art torque measurement systems have been susceptible to significant errors which impair the accuracy of such systems. As a result, there has been a long recognized need in the art to improve the torque measurement of such systems.

In general, prior art systems attempt to measure torque by measuring the pressure level (i.e., p.s.i.) of the pump which generates the pressurized operating fluid for the wrench. The p.s.i. output level of the pump is displayed and read on a gage to supposedly reflect the torque output of the wrench.

The above discussed prior art torque measurement systems are deficient and inaccurate in several respects. In a typical prior art system, the maximum torque produced by the tool is determined by manual adjustment of a pressure regulator in the hydraulic line which feed the drive end of the hydraulic cylinder which powers the tool. The operator usually refers to a table or graph furnished by the manufacturer to determine the approximate cylinder pressure for a given output torque. The operator then repeatedly operates control switches in a pendant to advance and then to retract the drive cylinder of the wrench to tighten the bolt. A ratchet in the wrench converts this reciprocating cylinder motiont into continuous clockwise or counterclockwise motion of the nut. The operator keeps operating the switches until the wrench stalls at the preselected pressure. Both the pressure selection and operation of the wrench takes operator skill and time.

Meanwhile a second mechanic must hold the reaction end of the wrench against a reaction surface on the workpiece. If he does not do this the wrench will not ratchet properly (because of backlash between drive bar and socket, socket and nut, etc.).

The torque produced by prior present hydraulic wrenches in determined by reading p.s.i. measurements on a hydraulic pressure gage on the pumping system which powers the wrench. One of the more significant problems with these prior art systems is that they sense and display pressure (p.s.i.) levels, whereas torque (ft. lbs.) is the true parameter of interest, because bolt tightening specifications are expressed in torque. Since a pump may be used with a variety of wrenches (developing different amount of torque for the same supply pressure), means must be provided to account for the different wrenches. Some systems merely provide a gate calibrated in pump pressure, plus supplemental conversion charts to convert pressure to torque for various wrenches. Other prior art systems attempt to present a torque readout or sorts by the use of a pressure gage marked in several torque ranges rather than in psi values. However, a different torque range or scale must be used for each wrench size, making the system susceptible to error and misinterpretation. All of this can be very confusing to and can be misread or misinterpreted by the operator, and can lead to incorrect torques on the bolts being tightened.

SUMMARY OF THE INVENTION

The above discussed and other problems and deficiencies of the prior art are eliminated or significantly reduced by the present invention. In accordance with the present invention, the parameter of interest, i.e., torque, is determined and displayed in a digital readout. By determining torque and presenting a digital readout of the measured torque, the present invention alleviates or eliminates the problems which made the prior art systems error prone and inaccurate.

In accordance with the present invention, torque is determined by a system which includes a transducer which converts the operating pressure of a hydraulic wrench to an analog electrical signal. That analog signal is then digitized, delivered as an input to a microprocessor or computer. The output of a temperature transducer is also digitized and delivered to the microprocessor to compensate for temperature of the pressure transducer. Another input informs the microprocessor or computer of the particular wrench being used in the system. The microprocessor or computer then operates on the input to produce an output signal commensurate with torque. That torque output signal is then delivered to and displayed on a numeric (or alpha/numeric) display as a direct readout of torque. The output from the microprocessor can be programmed to produce a torque output in any desired system of units (e.g. pound-feet or Newton-meters).

The system of the present invention has the principal advantage of presenting torque as a direct readout in a digital display. This does away with the need for the use of conversion charts or tables to convert psi to torque and eliminates a serious source of error in prior art systems. Also when the operator is adjusting the manually operated pressure relief valve to preset the cutoff torque to the wrench, the operator is guided by a real time direct digital display of the torque which each setting of the relief valve would produce, rather than being guided by readings on a pressure gage. As a result, the operator can adjust cutoff pressure to the nearest desired lb-ft (or equivalent), whereas with prior art systems the operator can only set the valve to the nearest cardinal point on the gage, which may be 25 to 50 lb-ft apart. The system of the present invention also has the dual capability to display pump pressure on the digital readout if that parameter is of interest. The system also is capable of direct digital readout of torque for a range of wrench sizes used with the system, thus eliminating the need for gages with overlaps or multiple displays for different wrenches.

The above discussed and other features and advantages of the present invention will be apparent to and understood by those skilled in the art from the following detailed description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Referring now to the drawings, wherein like elements are numbered alike in the several Figures:

FIG. 1 is a block diagram of the torque measurement and digital torque readout system of the present invention.

FIG. 2 is a functional diagram of the digital torque readout system of the present invention.

FIGS. 3A and 3B show a flow chart of the microprocessor or computer program for the digital torque readout system of the present invention.

FIG. 4 is a schematic showing signal conditoner and analog to digital logic circuitry for use in the system of the present invention.

FIG. 5 is a block diagram showing the microprocessor and associated components.

FIG. 5A is a schematic diagram of a power supply unit used in the present invention.

FIG. 6 is a block diagram of the selector switch and LCD display board used in the present invention.

DESCRIPTION OF THE INVENTION

Referring first to FIG. 1, a block diagram is shown of the overall system of the present invention. The system includes a conventional hydraulically powered torque wrench 10 (such as identified above) which is powered by a motor 12 and pump 14 supplied from a fluid reservoir 16. Pump 14 delivers pressurized hydraulic fluid to wrench 10 via a manually adjustable pressure relief valve 20, a 3 position 4 way valve 18 and drive and relief valve 22. A control pendant 24 (which may be suspended on a cable and be hand or foot operated, or may be mounted on the wrench or on some other part of the system) controls the position of valve 18 to operate wrench 10 in either a drive stroke or a return stroke. Manually adjustable pressure regulator 20 is set (and can be adjusted as may be required) to establish a maximum pressure level. Return relief valve 22 is typically set to operate at some relatively low pressure (e.g., 400 p.s.i.) to prevent overpressurization of the return side of the drive cylinder of the wrench. Wrench 10 includes a ratchet mechanism so that the wrench can be repeatedly cycled to tighten a fastener such as a nut or bolt. The elements 10-24 described above are all found in a prior art wrench operating system.

Still referring to FIG. 1, the system of the present invention also includes apparatus for determining and for the digital display of the real time torque level of the wrench. That apparatus includes a pressure transducer 26 which senses the pressure level on the drive side of the wrench and generates a voltage output signal. That voltage signal from transducer 26 is delivered to an analog to digital converter 28 (which includes a multiplexer 40, a comparator 42 and a D/A converter 45 (see FIGS. 2 and 4) which, in turn, is connected to a microprocessor 30. A temperature sensor 32 (an AD 590 transducer) senses the temperature at which the pressure transducer is operating and delivers a temperature input signal to microprocessor 30 which compensates for temperature deviation from a standard 75° F. "room temperature". A wrench size selection switch 34 delivers an input signal to microprocessor 30 based on the size of the wrench being used in the system. Microprocessor 30 is programmed to process the various input signals and generate a digital output of the real time torque level of the wrench as it operates which is displayed on a liquid crystal (LCD) display 31.

Referring now to FIG. 2, a functional diagram of the torque measuring and display system is shown. Pressure transducer 26 is a half bridge strain gage transducer such as an Model MFP 0-10,000 transducer available from DJ Instruments. The output signal from transducer 26 is balanced against a pressure offset trim bridge 36, and the signals from transducer 26 and trim bridge 36 are delivered to an instrumentation amplifier 38. The output from instrumentation amplifier 38 is delivered to an analog multiplexer 40 which also receives an input signal from temperature transducer 32. Based on a control signal from microprocessor 30, multiplexer 40 delivers either the pressure signal or the temperature signal to a comparator 42. Microprocessor 30 delivers digital signals to digital to analog converter 45 which, in turn, delivers analog voltage to comparator 42. Comparator 42 compares the input from multiplexer 40 (either pressure or temperature signals) with the input from D/A converter 45. When the input to comparator 42 from multiplexer 40 exceeds the output from D/A converter 45, the output state of comparator 42 delivers a low logic signal to microprocessor 30. When the input to comparator 42 from multiplexer 40 is lower than the output from D/A converter 45, the output state of comparator 42 delivers a high logic signal to microprocessor 30. The microprocessor 30 determines the pressure or temperature level by matching the D/A converter output to the pressure or temperature sensor.

Wrench size switch 34 also delivers an input signal to microprocessor 30 to inform the microprocessor of the size of the wrench being operated. The signal from selector switch 34 determines a ratio or multiplication factor and offset factor which is stored in permanent memory and which is used by microprocessor 30 to convert the pressure information (as temperature compensated) to a torque value. Microprocessor 30 then generates a torque signal which is delivered to and displayed on LCD display 25.

Microprocessor 30 also has the capacity to drive other digital outputs 31 and communicate with an external computer 33.

Referring now to a combined consideration of FIGS. 4, 5 and 6, microprocessor 30 is a 6805 CMOS microprocessor that provides for control of LCD display 25, and measurement of temperature and pressure. Microprocessor 30 contains 128 bytes of random access memory (RAM) and is interfaced with a 2K 2716 erasible programmable read only memory (EPROM) 48. Measurement and control functions are provided by 16 input/output (I/O) lines that are an integral part of microprocessor 30. The microprocessor system also includes an output latch 50 with tri-state outputs between EPROM 48 and microprocessor 30. Twelve outputs from microprocessor 30 are provided for control using two 6 bit 4174 flip-flop latches 52, 54. Ten of those outputs also interface with 10 bit digital to analog converter 45 (ICL 7533), (see FIG. 4). The system regulates its own power to +5 volts consuming a maximum of 50 ma of current at this voltage. The microprocessor is driven by a 3.79 MH oscillator 56.

Referring particularly to FIG. 4, the pressure signal from gage pressure transducer 26 is delivered to instrumentation amplifier 38. The output from transducer 26 (which is a half bridge transducer) varies from approximately 2.4 to 2.5 mv over a pressure range of from 0 to 10,000 p.s.i. That output is balanced against a pressure offset trim resistance bridge, and the difference is taken by amplifier 38. The output from amplifier 38 (which is an analog voltage signal commensurate with wrench operating pressure) is delivered to a 4501 analog multiplexer 40. Multiplexer 58 also receives analog voltage inputs commensurate with pressure transducer temperature from temperature transducer 32. Multiplexer 40 is connected to and receives control signals from microprocessor 30 (on the lines marked Mux A Control and Mux B control). As determined by the software program, microprocessor 30 will signal multiplexer 40 to pass either the pressure input voltage signal or the temperature input voltage signal to comparator 42 (LM311).

The analog voltage signal (pressure or temperature) from multiplexer 40 is determined by comparator 42, the 10 bit digital to analog converter 45, and the microprocessor 30. The conversion is controlled by a software algorithm that applies a binary search of digital voltage values to D/A converter 45 for delivery to comparator 42. When the input from D/A converter 45 to comparator 42 is within 1 bit of the input (i.e., pressure or temperature signal) from multiplexer 40 to comparator 42, the digital value of the pressure or temperature is equivalent to that digital value applied to the D/A converter 45. This informs the microprocessor of the pressure or temperature level by equating it to the voltage level in converter 45 set by the microprocessor.

Upon determining the digital voltage, the system software causes the microprocessor 30 to repeat the comparison process 32 times to obtain an average voltage level of the pressure or temperature signal over 5 milliseconds of time. Then, as an additional filtering step, the software causes 16 repeats of the 5 ms (32 readings) step for both temperature and pressure readings prior to the steps of temperature compensation and conversion of pressure readings to torque measurement (both of which are accomplished in the microprocessor under control of the algorithms of the software program).

A mulitple position selection switch 60 (see FIG. 6) interfaces with microprocessor 30 to compute and display torque for wrenches of different sizes. In the present system, switch 60 is an 8 position switch to be used to display torque readings for 7 different size wrenches (switch torque positions 2-8); and one switch position is used for display of pressure when it is desired to know that parameter. Switch 60 is connected to a 4051 analog switch multiplexer 62. Switch multiplexer 62 receives three TTL digital signals from microprocessor 30 (Switch A Control, Switch B Control, Switch C Control) at inputs marked A, B and C, respectively. All of the positions of switch 60 are connected to one of eight input channels of multiplexer 62, the output of which, in turn, is connected to the "Switch Input"pin on microprocessor 30. Each individual switch position (positions 1-8) of switch 60 is connected to the channel "OUT"by a different binary code on the pins A, B, C of multiplexer 62 from the microprocessor, thus providing eight switch position indicators. Microprocessor 30 interrogates switch multiplexer 62 at the rate of 25 times per second to determine the position at which rotary switch 60 is set. Under the control of the software program, calibration or conversion coefficients are applied to the pressure signals to convert them to torque values, which are then displayed on the LCD display system.

Referring to FIG. 6, microprocessor 30 is connected through 5 4543 display drivers 64-72 to an LCD display 74. The drivers 64-72 convert BCD outputs from microprocessor 30 to the 7 segments comprising each digit to be displayed. A clock generated by timed interrupts within the microprocessor system (from pin 10 on latch 54) is used to generate an AC clock to the LCD display to prevent burn-in of digits on the LCD. All other tasks in the system are also scheduled by interrupts generated by this 25 Hz clock. The output to LCD 74 is updated every 16 interrupts (about 0.6 seconds) under control of the program software.

It should be noted that the system of the present invention also simplifies and makes more accurate the preset operation whereby pressure relief valve is adjusted to set the maximum operating pressure of the system. In the present system, the operator sees the pressure level digitally displayed in real time as he sets valve 20. Furthermore, the operator can accurately set valve 20 to a desired level rather than being limited to the cardinal points on a gage.

The digital torque readout (DTR) system of the present invention should be calibrated for pressure and temperature before initial operation or if there is reason to believe the temperature or pressure transducer has drifted.

Calibration is effected by selection of a special operating mode (under control of the microprocessor and the system software) through selector switch 60. Microprocessor 30 is powered, whereupon display 74 will show an array of 5 digits of 8. Select switch 60 is then cycled from position 1 to position 2 and back to position 1. Selector position 1 will then display pressure and position 6 (torque position 5) will display the temperature correction factor multiplied by 256.

Temperature calibration is effected first with switch 60 in position 6, at which the temperature will be displayed on LCD 74, with 256 being equivalent to 75° F. room temperature. Temperature calibration is then carried out by adjusting a potentiometer 76 in the circuit of comparator 42 until the temperature reading is 256 (75° F., i.e., standard "room temperature"). Thereafter, during normal operation of the system, temperature transducer 32 compensates for operating temperatures different from 75° F.

After temperature calibration is done, the system is calibrated for pressure. To effect pressure calibration, the linear behavior of pressure transducer 26 must be matched to a calibrated pressure gage.

The offset and gain of each individual transducer is adjusted by potentiometers 80 and 78, respectively, until the linear behavior of the transducer is within 2% of the actual pressure.

The DTR system of the present invention is controlled by microprocessor 30 and the software program in EPROM 48. Much of the program and its operation have been described in the course of the foregoing description. The entire program stored in EPROM 48 is set forth in Table 1 below (attached hereto as an appendix). The program of Table 1 has five columns. Column (1) is a 4 digit hexadecimal address column; column (2) is a column showing the 4 digit hexadecimal machine code representation of columns (3) and (4); column (3) shows the operand or op code; column (4) shows the argument; column (5) lists remarks briefly explaining the nature of the operation being carried out. Those skilled in the art will find the program listed in Table 1 to be a complete and precise description of each step carried out in the program of the present invention. Accordingly, for purposes of clarity and brevity, only the major operations carried out by the program will be described in general terms (in addition to the program description already given in the foregoing discussion of hardware and operation).

Referring to FIGS. 3A and 3B, a flow chart of the principal features of the program are shown. FIG. 3A shows the program for processor initialization and calibration. FIG. 3B shows the main operating program.

Referring first to FIG. 3A, on powering up the system, a display of five 8 digits appears on display 74. Then, the program checks to see if the calibration mode has been initiated. The 25 Hz timer interrupt clock is started and goes to an idle hoop if the calibration mode has been initiated.

If the calibration mode has not be initiated, a timer interrupt signal is delivered to flip the state of the display clock. If the clock is high, the program directs the micorprocessor to determine the pressure and temperature readings (this is done 32 times); and an attempt is made to repeat for 16 times the 32 readings of pressure and temperature. The 16 repeats are sychronized to the timer interrupt signal. After the 16th reading, the microprocessor reads the position of selector switch 60, then temperature correction is applied to the pressure reading, and the pressure is converted to torque per the conversion algorithm in the program.

If the clock is low and after the 16th reading, a signal is delivered to update the LCD display. After the 16th reading, a signal is delivered to update the display before receipt of a timer interrupt signal, inputs are delivered to update the display on the display 74. If an external computer is connected to the system, signals may also be delivered to it when the display is updated. As described previously, the main part of the program is interrupt driven by the 25 Hz clock in the system.

Those skilled in the art will understand that the present invention presents a unique method and apparatus for determining actual torque beinga pplied to a fastening element by a powered wrench. The torque is determined in real time and presented as a digital display. This invention overcomes problems of long standing and metts a long felt need in the art. Furthermore, this invention simplifies operation of power wrenches, improves their accuracy and reliability, and eliminates serious sources of error in the prior art.

By providing for direct digital readout of torque, the present invention overcomes the several previously discussed problems of the prior art associated with the use of pressure gage readouts.

While preferred embodiments have been shown and described, various modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustrations and not limitation. ##SPC1##